Honeycomb filter

ABSTRACT

A honeycomb filter, including:
         a honeycomb structure,   wherein the honeycomb structure further includes a platinum group element-containing catalyst layer,   the platinum group element-containing catalyst layer is disposed only on a side of an inner surface of the partition walls surrounding the inflow cells, and   the platinum group element-containing catalyst layer is disposed in a range of at least up to 35% with respect to an overall length of the cells starting from the inflow end face and is not disposed in a range of at least up to 30% with respect to the overall length of the cells starting from the outflow end face, in an extending direction of the cells of the honeycomb structure.

The present application is an application based on JP-2018-066813 filedon Mar. 30, 2018 with Japan Patent Office, the entire contents of whichare incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a honeycomb filter. More particularly,the present invention relates to a honeycomb filter which is excellentin trapping performance for trapping particulate matter contained inexhaust gas and excellent in purification performance for purifyingharmful components contained in the exhaust gas.

Description of the Related Art

In recent years, regulations on removal of particulate matter containedin exhaust gas emitted from a gasoline engine are getting stricteraround the world, and a honeycomb filter having a honeycomb structurehas been used as a filter for removing particulate matter. Hereinafter,the particulate matter may be referred to as “PM”. The PM is anabbreviation for “the particulate matter”.

Examples of the honeycomb filter can include a honeycomb filter whichincludes a honeycomb structure having porous partition walls defining aplurality of cells and plugging portions plugging an end portion of anyone of the cells. In such a honeycomb filter, each of the porouspartition walls is structured to serve as a filter for removing the PM.Specifically, the PM-containing exhaust gas is introduced from an inflowend face of the honeycomb filter, the PM is trapped by the porouspartition walls to be filtered, and then the purified exhaust gas isemitted from an outflow end face of the honeycomb filter. By doing so,the PM in the exhaust gas can be removed.

For the purpose of improving the purification performance of such ahoneycomb filter, loading a catalyst for purifying the exhaust gas ontothe porous partition wall is performed (see Patent Document 1, forexample). Examples of the catalyst for purifying the exhaust gas caninclude a platinum group element-containing catalyst constituted by anexhaust gas purifying catalyst containing a platinum group element.Hereinafter, the platinum group element-containing catalyst may bereferred to as a “PGM catalyst”. “PGM” is an abbreviation for “platinumgroup metal”. The PGM includes ruthenium, rhodium, palladium, osmium,iridium, and platinum.

[Patent Document 1] JP-A-2015-066536

SUMMARY OF THE INVENTION

In the honeycomb filter for the gasoline engine, it has been studied touse the honeycomb structure in which a porosity of partition wall ishigh in order to suppress an increase in pressure loss. When the PGMcatalyst is loaded onto the partition walls of such a honeycombstructure, the PGM catalyst is loaded so as to be filled in the pores ofthe porous partition walls.

Conventionally, the honeycomb filter using the honeycomb structurehaving the high porosity has a problem in that the trapping performancefor trapping the PM deteriorates when the PGM catalyst is loaded. Thefollowing reasons are conceivable as a cause of the deterioration in thetrapping performance. When the PGM catalyst is loaded onto the partitionwalls in which a porosity is high, the PGM catalyst is filled in orderstarting from pores with a relatively smaller pore diameter among thepores of the partition walls. For this reason, in the partition wallsonto which a predetermined amount of PGM catalyst is loaded, the poreswith a relatively smaller pore diameter are closed by the PGM catalystand the pores with a relatively larger pore diameter remain.Hereinafter, the pores with a relatively smaller pore diameter arereferred to as “small pore”, and the pores with a relatively larger porediameter are referred to as “large pore”. In the honeycomb structure inwhich a porosity is high, when the small pores of the partition wall arepreferentially closed by the PGM catalyst, the ratio of the large poresof the partition walls is increased and the flow of exhaust gaspermeating the partition walls concentrates on the large pores. That is,the exhaust gas becomes difficult to flow in the small pores whichcontribute to the improvement of the trapping performance, and as aresult the trapping performance of the honeycomb filter deteriorates.

The present invention has been made in view of such problems of theprior art. According to the present invention, there is provided ahoneycomb filter which is excellent in trapping performance for trappingPM contained in exhaust gas and excellent in purification performancefor purifying harmful components contained in the exhaust gas.

According to the present invention, there is provided a honeycomb filteras shown below.

According to a first aspect of the present invention, a honeycomb filteris provided including: a honeycomb structure which has porous partitionwalls disposed so as to surround a plurality of cells as throughchannels of fluid extending from an inflow end face to an outflow endface; and

plugging portions disposed to plug either one of end portions of each ofthe cells on the side of the inflow end face or the side of the outflowend face,

wherein the cells in which the plugging portions are arranged in an endportion on the side of the outflow end face and which are opened on theside of the inflow end face are defined as inflow cells,

the cells in which the plugging portions are arranged in end portion onthe side of the inflow end face and which are opened on the side of theoutflow end face are defined as outflow cells,

the honeycomb structure further includes a platinum groupelement-containing catalyst layer constituted by an exhaust gaspurifying catalyst containing a platinum group element,

the platinum group element-containing catalyst layer is disposed only ona side of an inner surface of the partition walls surrounding the inflowcells, and

the platinum group element-containing catalyst layer is disposed in arange of at least up to 35% with respect to an overall length of thecells starting from the inflow end face and is not disposed in a rangeof at least up to 30% with respect to the overall length of the cellsstarting from the outflow end face, in an extending direction of thecells of the honeycomb structure.

According to a second aspect of the present invention, the honeycombfilter according to the above first aspect is provided, wherein aporosity of the platinum group element-containing catalyst layer is from50 to 90%.

According to a third aspect of the present invention, the honeycombfilter according to the above first or second aspects is provided,wherein a thickness of the platinum group element-containing catalystlayer is from 10 to 40 μm.

According to a fourth aspect of the present invention, the honeycombfilter according to any one of the above first to third aspects isprovided, wherein the platinum group element-containing catalyst layeris a catalyst layer containing an oxide of at least one element selectedfrom the group consisting of aluminum, zirconium, and cerium.

According to a fifth aspect of the present invention, the honeycombfilter according to any one of the above first to fourth aspects isprovided, wherein in a cross section orthogonal to the extendingdirection of the cells of the honeycomb structure, a range within 60% ofa length from a center of gravity of the cross section to acircumferential edge of the cross section is defined as a centralportion of the cross section, and

the platinum group element-containing catalyst layer is disposed on thepartition walls present at the central portion of the cross section.

According to a sixth aspect of the present invention, the honeycombfilter according to any one of the above first to fourth aspects isprovided, wherein in the cross section orthogonal to the extendingdirection of the cells of the honeycomb structure, the platinum groupelement-containing catalyst layer is disposed on the partition wallswhich surround the inflow cells in an entire area of the cross section.

The honeycomb filter according to the present invention increases thetrapping performance for trapping the PM contained in exhaust gas andthe purification performance for purifying the harmful componentscontained in the exhaust gas.

That is, in the honeycomb filter according to the present invention, the“platinum group element-containing catalyst layer” is preferentiallydisposed on the side of the inflow end face of the honeycomb structure,and the “platinum group element-containing catalyst layer” is notdisposed on the side of the outflow end face of the honeycomb structure.Therefore, the partition walls on the side of the outflow end face intowhich a large amount of gas flows favorably function as a filteringmaterial for trapping the PM, and the trapping performance can beimproved by the partition walls on the side of the outflow end face. Inaddition, since the platinum group element-containing catalyst layer isdisposed only on the side of inner surface of the partition wallssurrounding the inflow cells, the contact of the platinum groupelement-containing catalyst layer with the exhaust gas is promoted inthe inflow cells, and the purification performance can be effectivelyimproved. As described above, the honeycomb filter of the presentinvention is configured so as to favorably share the functions of thepurification performance and the trapping performance between the sideof the inflow end face and the side of the outflow end face of thehoneycomb structure. That is, the side of the inflow end face of thehoneycomb structure is mainly specialized for the function of improvingthe purification performance by the platinum group element-containingcatalyst layer, and the side of the outflow end face of the honeycombstructure is mainly specialized for the function of improving thetrapping performance by the porous partition walls.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view schematically showing a first embodiment ofa honeycomb filter of the present invention;

FIG. 2 is a plane view of a side of an inflow end face of the honeycombfilter shown in FIG. 1;

FIG. 3 is a plane view of a side of an outflow end face of the honeycombfilter shown in FIG. 1;

FIG. 4 is a cross-sectional view schematically showing a cross sectiontaken along line A-A′ of FIG. 2;

FIG. 5 is a plane view of a side of an inflow end face schematicallyshowing a second embodiment of a honeycomb filter of the presentinvention; and

FIG. 6 is a cross-sectional view schematically showing a cross sectiontaken along line B-B′ of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, embodiments of the present invention will be described, butthe present invention is not limited to the following embodiments.Therefore, it should be understood that the following embodimentsappropriately modified, improved, and the like based on the ordinaryknowledge of a person skilled in the art without deviating from thepurpose of the invention fall within the scope of the present invention.

(1) Honeycomb Filter (First Embodiment)

A first embodiment of a honeycomb filter of the present invention is ahoneycomb filter 100 as shown in FIGS. 1 to 4. Here, FIG. 1 is aperspective view schematically showing the first embodiment of thehoneycomb filter of the present invention. FIG. 2 is a plane view of aside of an inflow end face of the honeycomb filter shown in FIG. 1. FIG.3 is a plane view of a side of an outflow end face of the honeycombfilter shown in FIG. 1. FIG. 4 is a cross-sectional view schematicallyshowing a cross section taken along line A-A′ of FIG. 2.

As shown in FIGS. 1 to 4, the honeycomb filter 100 according to thepresent embodiment includes a honeycomb structure 4 and pluggingportions 5. The honeycomb structure 4 has porous partition walls 1disposed so as to surround a plurality of cells 2 as through channels offluid extending from an inflow end face 11 to an outflow end face 12.The honeycomb structure 4 shown in FIGS. 1 to 4 is formed in a roundpillar shape having the inflow end face 11 and the outflow end face 12as both end faces, and further has a circumferential wall 3 on acircumferential side face thereof. That is, the circumferential wall 3is disposed so as to surround the partition walls 1 disposed in a shapeof lattice.

The plugging portions 5 are disposed so as to plug either one of endportions of each of the cells 2 on the side of the inflow end face 11 orthe side of the outflow end face 12. Hereinafter, among a plurality ofcells 2, the cells 2 in which the plugging portions 5 are arranged in anend portion on the side of the outflow end face 12 and which are openedon the side of the inflow end face 11 are defined as “inflow cells 2 a”.In addition, among the plurality of cells 2, the cells in which theplugging portions 5 are arranged in end portion on the side of theinflow end face 11 and which are opened on the side of the outflow endface 12 are defined as “outflow cells 2 b”. In the honeycomb filter 100according to the present embodiment, it is preferable that the inflowcell 2 a and the outflow cell 2 b are alternately disposed via thepartition walls 1.

In the honeycomb filter 100, the honeycomb structure 4 is configured asfollows. That is, the honeycomb structure 4 further includes a platinumgroup element-containing catalyst layer 14 constituted by an exhaust gaspurifying catalyst containing a platinum group element. The platinumgroup element-containing catalyst layer 14 is disposed only on a side ofan inner surface of the partition walls 1 surrounding the inflow cells 2a. In addition, the platinum group element-containing catalyst layer 14is disposed in a range of at least up to 35% with respect to an overalllength of the cells 2 starting from the inflow end face 11 in anextending direction of the cells 2 of the honeycomb structure 4. Theplatinum group element-containing catalyst layer 14 is not disposed in arange of at least up to 30% with respect to the overall length of thecells 2 starting from the outflow end face 12. The overall length of thecells 2 refers to a length from the inflow end face 11 to the outflowend face 12 of the honeycomb structure 4 (in other words, from theoutflow end face 12 to the inflow end face 11 of the honeycomb structure4). The “disposed only on the side of the inner surface of the partitionwalls 1” means that in a thickness direction of the partition walls 1,the platinum group element-containing catalyst is not present between0.1 T and 1.0 T starting from a position of the above 0.1 T (where, Tindicates the thickness of the partition walls 1) in the thicknessdirection of the partition walls 1 from the inner surface of thepartition walls 1.

Here, the platinum group element includes ruthenium, rhodium, palladium,osmium, iridium, and platinum. Hereinafter, the platinum group elementmay be referred to as “PGM”.

The platinum group element-containing catalyst layer 14 is disposed onlyon the side of the inner surface of the partition walls 1 surroundingthe inflow cells 2 a and in a range of at least up to 35% with respectto the overall length of the cells 2 starting from the inflow end face11. The platinum group element-containing catalyst layer 14 is acatalyst coating layer which is formed by coating the platinum groupelement-containing catalyst on a predetermined surface of the partitionwalls 1.

The honeycomb filter 100 includes the honeycomb structure 4 whichfurther includes the platinum group element-containing catalyst layer 14as described above, and is excellent in trapping performance of trappingthe PM and excellent in purification performance for purifying harmfulcomponents contained in the exhaust gas.

That is, in the honeycomb filter 100, the partition walls 1 on the sideof the outflow end face 12 in which a large amount of gas flowsfavorably function as the filtering material for trapping the PM, andthe trapping performance can be improved by the partition walls 1 on theside of the outflow end face 12. In addition, since the platinum groupelement-containing catalyst layer 14 is disposed only on the side of theinner surface of the partition walls 1 surrounding the inflow cells 2 a,the contact of the platinum group element-containing catalyst layer 14with the exhaust gas is promoted in the inflow cells 2 a, and thepurification performance can be effectively improved. As describedabove, the honeycomb filter 100 is configured so as to favorably sharethe functions of the purification performance and the trappingperformance between the side of the inflow end face 11 and the side ofthe outflow end face 12 of the honeycomb structure 4. That is, the sideof the inflow end face 11 of the honeycomb structure 4 is mainlyspecialized for the function of improving the purification performanceby the platinum group element-containing catalyst layer 14, and the sideof the outflow end face 12 of the honeycomb structure 4 is mainlyspecialized for the function of improving the trapping performance bythe porous partition walls 1.

If the platinum group element-containing catalyst layer 14 is alsodisposed at portions other than the inner surface of the partition walls1 surrounding the inflow cells 2 a, the pressure loss of the honeycombfilter 100 may be increased. In addition, although the catalystcontaining the platinum group element has the excellent catalystperformance for the exhaust gas purification, scarcity is high and anindustrial value is also high. Therefore, the platinum groupelement-containing catalyst layer 14 is disposed only on thepredetermined surface of the partition walls 1, such that themanufacturing cost of the honeycomb filter 100 can be reduced.

The porosity of the platinum group element-containing catalyst layer 14is preferably from 50 to 90%, more preferably from 60 to 80%, andparticularly preferably from 60 to 70%. If the porosity of the platinumgroup element-containing catalyst layer 14 is less than 50%, thepressure loss may be increased. On the other hand, when the porosity ofthe platinum group element-containing catalyst layer 14 exceeds 90%, thetrapping efficiency may deteriorate.

An average pore diameter of the platinum group element-containingcatalyst layer 14 is preferably from 1 to 7 μm, more preferably from 1to 5 μm, and particularly preferably from 1 to 3 μm.

The porosity and the average pore diameter of the platinum groupelement-containing catalyst layer 14 can be measured by the followingmethod. First, a cross-sectional portion of the platinum groupelement-containing catalyst layer 14 is observed by a scanning electronmicroscope (hereinafter, also referred to as “SEM”) to acquire the SEMimage thereof. The SEM image is magnified to 200 times for observation.The SEM is an abbreviation for “scanning electron microscope”. As thescanning electron microscope, for example, a scanning electronmicroscope “model number: S3200-N” manufactured by HitachiHigh-Technologies Corporation can be used. Next, a substantial portionof the platinum group element-containing catalyst layer 14 and a voidportion in the platinum group element-containing catalyst layer 14 arebinarized by analyzing the acquired SEM image. Then, a percentage of aratio of the void portion in the platinum group element-containingcatalyst layer 14 with respect to a total area of the substantialportion and the void portion of the platinum group element-containingcatalyst layer 14 is calculated, and the calculated value is set to bethe porosity of the platinum group element-containing catalyst layer 14.In addition, separately, a hollow wall between the respective particlediameters in the SEM image is binarized, and a size of the hollow wallis directly measured with a scale, and the pore diameter of the platinumgroup element-containing catalyst layer 14 is calculated. An averagevalue of the calculated pore diameters is set to be an average porediameter of the platinum group element-containing catalyst layer 14.

In addition, the platinum group element-containing catalyst layer 14 ispreferably a catalyst layer constituted by a platinum groupelement-containing catalyst having a particle diameter of 1 to 10 μm.With such a configuration, the platinum group element-containingcatalyst layer 14 can effectively be disposed on the inner surface ofthe partition walls 1 surrounding the inflow cells 2 a.

The thickness of the platinum group element-containing catalyst layer 14is preferably from 10 to 40 μm, more preferably from 20 to 35 μm, andparticularly preferably from 20 to 30 μm. If the thickness of theplatinum group element-containing catalyst layer 14 is less than 10 μm,it is not preferable because the contact of the platinum groupelement-containing catalyst layer 14 with gas is lowered. On the otherhand, if the thickness of the platinum group element-containing catalystlayer 14 exceeds 40 μm, it is not preferable because the pressure lossmay be increased.

The thickness of the platinum group element-containing catalyst layer 14can be measured by the following method. First, a cross-sectionalportion of the platinum group element-containing catalyst layer 14 isobserved by a scanning electron microscope to acquire the SEM imagethereof. Next, from the acquired SEM image, the thickness of theplatinum group element-containing catalyst layer 14 is directly measuredusing the scale.

It is preferable that the platinum group element-containing catalystlayer 14 is a catalyst layer containing an oxide of at least one elementselected from the group consisting of aluminum, zirconium, and cerium.It is preferable that the catalyst layer containing such an oxidecontains from 1 to 3% by mass of a platinum group element with respectto the total mass of the catalyst layer. A composition of the platinumgroup element-containing catalyst layer 14 can be measured by, forexample, fluorescent X-ray analysis (XRF; X-ray fluorescence).Specifically, the composition analysis of the platinum groupelement-containing catalyst layer 14 can be performed by detectingfluorescent X-rays intrinsic to each element generated by irradiating asample with X-rays.

The platinum group element-containing catalyst layer 14 is disposed in arange of at least up 35% with respect to the overall length of the cells2 starting from the inflow end face 11, and is not disposed in a rangeof at least up to 30% with respect to the overall length of the cells 2starting from the outflow end face 12. The range in which the platinumgroup element-containing catalyst layer 14 is disposed may be, forexample, up to 40%, up to 50%, and up to 60% with respect to the overalllength of the cells 2 starting from the inflow end face 11. In addition,the range in which the platinum group element-containing catalyst layer14 is not disposed is preferably at least 35% and more preferably atleast 40% with respect to the overall length of the cells 2 startingfrom the outflow end face 12. With such a configuration, it is possibleto increase the trapping efficiency of the honeycomb filter 100 andeffectively suppress the increase in the pressure loss of the honeycombfilter 100.

In the honeycomb filter 100 shown in FIGS. 1 to 4, in a cross sectionorthogonal to the extending direction of the cells 2 of the honeycombstructure 4, the platinum group element-containing catalyst layer 14 isdisposed in the entire area of the cross section. However, the platinumgroup element-containing catalyst layer 14 may be disposed on the sideof the inner surface of the partition walls 1 surrounding at least oneof inflow cells 2 a in the cross section. That is, in a range of atleast up to 60% with respect to the overall length starting from theinflow end face 11 of the honeycomb structure 4, the platinum groupelement-containing catalyst layer 14 may be disposed on the side of theinner surface of the partition walls 1 surrounding at least one of theinflow cells 2 a.

The porosity of the partition walls 1 of the honeycomb structure 4 ispreferably from 50 to 70%, more preferably from 55 to 65%, andparticularly preferably from 60 to 65%. The porosity of the partitionwalls 1 is a value measured by a mercury porosimetry. The porosity ofthe partition walls 1 can be measured using, for example, AutoPore 9500(product name) manufactured by Micromeritics Instrument Corp. If theporosity of the partition walls 1 is less than 50%, it is not preferablebecause a permeation resistance of the partition walls 1 is increasedand the pressure loss is increased. If the porosity of the partitionwalls 1 exceeds 70%, it is not preferable because the strength isremarkably decreased.

The average pore diameter of the partition walls 1 is preferably from 10to 25 μm, more preferably from 10 to 20 and particularly preferably from15 to 20 μM. The average pore diameter of the partition walls 1 is avalue measured by the mercury porosimetry. The average pore diameter ofthe partition walls 1 can be measured using, for example, AutoPore 9500(product name) manufactured by Micromeritics Instrument Corp. If theaverage pore diameter of the partition walls 1 is less than 10 μm, it isnot preferable because a permeation resistance of the partition wall 1is increased and the pressure loss is increased. If the average porediameter of the partition wall 1 exceeds 25 μm, it is not preferablebecause the gas flow concentrates on the portion of the large pore andtherefore the trapping efficiency deteriorates.

In the honeycomb structure 4, the thickness of the partition walls 1 ispreferably from 0.15 to 0.38 mm, more preferably from 0.18 to 0.33 mm,and particularly preferably from 0.20 to 0.31 mm. The thickness of thepartition walls 1 can be measured using, for example, the scanningelectron microscope or the microscope. If the thickness of the partitionwalls 1 is less than 0.15 mm, the sufficient strength may not beobtained. On the other hand, if the thickness of the partition walls 1exceeds 0.38 mm, the pressure loss may be increased when the catalyst isloaded onto the partition walls 1.

The shape of the cells 2 formed in the honeycomb structure 4 is notparticularly limited. For example, in the cross section orthogonal tothe extending direction of the cells 2, the shape of the cells 2 may bea polygon, a circle, an ellipse, or the like. Examples of the polygoncan include a triangle, a quadrangle, a pentagon, a hexagon, an octagonand the like. The shape of the cells 2 is preferably a triangle, aquadrangle, a pentagon, a hexagon, or an octagon. As for the shape ofthe cells 2, all the cells 2 may have the same shape, or the cells 2 mayhave different shapes each other. For example, although not shown,quadrangular cells and octagonal cells may be mixed. As for the size ofthe cells 2, all the cells 2 may have the same size, or the cells 2 mayhave different sizes each other. For example, although not shown, of aplurality of cells, some cells may have a larger size, and the othercells may have a smaller size. In the present invention, the cell meansa space surrounded by the partition walls.

A cell density of the cells 2 defined by the partition walls 1 ispreferably from 31 to 54 cells/cm², and more preferably from 39 to 47cells/cm². With such a configuration, the honeycomb filter can besuitably used as a filter for trapping PM in exhaust gas emitted from anengine of an automobile or the like.

The circumferential wall 3 of the honeycomb structure 4 may be formedintegrally with the partition walls 1 or may be a circumferentialcoating layer formed by coating a circumferential coating material so asto surround the partition walls 1. Although not shown, at the time ofthe manufacturing, the circumferential coating layer may be provided onthe circumferential side of the partition walls after the partitionwalls are integrally formed with the circumferential wall and then theformed circumferential wall is removed by the known methods such asgrinding processing.

The shape of the honeycomb structure 4 is not particularly limited. Theshape of the honeycomb structure 4 may include a pillar shape in whichthe inflow end face 11 and the outflow end face 12 include a circularshape, an elliptical shape, and a polygonal shape.

The size of the honeycomb structure 4, for example, the length in theextending direction of the cells 2 of the honeycomb structure 4(hereinafter, also referred to as “overall length”) or the size of thecross section (hereinafter also referred to as “cross-sectional area”)orthogonal to the extending direction of the cells 2 of the honeycombstructure 4 is not particularly limited. Each size may be appropriatelyselected so as to obtain the optimum purification performance at thetime of using the honeycomb filter 100. The overall length of thehoneycomb structure 4 is preferably from 90 to 160 mm, and morepreferably from 120 to 140 mm. In addition, the cross-sectional area ofthe honeycomb structure 4 is preferably from 8000 to 16000 mm², and morepreferably from 10000 to 14000 mm².

The material of the partition walls 1 preferably is at least oneselected from the group consisting of cordierite, silicon carbide, asilicon-silicon carbide based composite material, mullite, alumina,aluminum titanate, silicon nitride, and silicon carbide-cordierite basedcomposite material. The material constituting the partition walls 1 ispreferably a material containing 30% by mass or more, more preferably amaterial containing 40% by mass or more, and particularly preferably amaterial including 50% by mass or more of the materials listed in theabove group. In the honeycomb filter 100 of the present embodiment, thematerial constituting the partition walls 1 is particularly preferablycordierite.

(2) Honeycomb Filter (Second Embodiment)

Next, a second embodiment of a honeycomb filter according to the presentinvention will be described below. The second embodiment of a honeycombfilter according to the present invention is a honeycomb filter 200 asshown in FIGS. 5 and 6. Here, FIG. 5 is a plane view of a side of aninflow end face schematically showing the second embodiment of thehoneycomb filter according to the present invention. FIG. 6 is across-sectional view schematically showing a cross section taken alongline B-B′ of FIG. 5.

As shown in FIGS. 5 and 6, the honeycomb filter 200 according to thepresent embodiment is a honeycomb filter 200 which includes a honeycombstructure 24 and plugging portions 25. The honeycomb structure 24 hasporous partition walls 21 disposed so as to surround a plurality ofcells 22 as through channels of fluid extending from an inflow end face31 to an outflow end face 32. A circumferential side surface of thehoneycomb structure 24 is further provided with a circumferential wall23 so as to surround the partition walls 21.

The plugging portions 25 are disposed so as to plug either one of endportions of each of the cells 22 on the side of the inflow end face 31or the side of the outflow end face 32. The cell 22 in which theplugging portions 25 are disposed at the end portion on the side of theoutflow end face 32 is defined as an “inflow cells 22 a” and the cell 22in which the plugging portions 25 are disposed at the end portion on theside of the inflow end face 31 is defined as an “outflow cells 22 b”.

In addition, in the honeycomb filter 200, the honeycomb structure 24further includes a platinum group element-containing catalyst layer 34constituted by an exhaust gas purifying catalyst containing a platinumgroup element. The platinum group element-containing catalyst layer 34is disposed only on a side of an inner surface of the partition walls 21surrounding the inflow cells 22 a. Furthermore, the platinum groupelement-containing catalyst layer 34 is disposed in a range of at leastup 35% with respect to the overall length of the cells 22 starting fromthe inflow end face 31, and is not disposed in a range of at least up to30% with respect to the overall length of the cells 22 starting from theoutflow end face 32.

In the honeycomb filter 200, the platinum group element-containingcatalyst layer 34 is disposed on the partition walls 21 present in acentral portion 38 of the honeycomb structure 24. That is, the platinumgroup element-containing catalyst layer 34 is disposed only on a side ofan inner surface of the partition walls 21 surrounding the inflow cells22 a among the partition walls 21 present in the central portion 38.Here, in a cross section orthogonal to the extending direction of thecells 22 of the honeycomb structure 24, the central portion 38 means arange within 60% of a length from a center of gravity of the crosssection to a circumferential edge of the cross section. That is, in thehoneycomb filter 200 according to the present embodiment, the platinumgroup element-containing catalyst layer 34 is preferentially disposedonly at the “central portion 38” in the cross section of theabove-described honeycomb structure 24, and the platinum groupelement-containing catalyst layer 34 is not disposed at portions otherthan the central portion 38.

In the honeycomb filter 200, since the platinum group element-containingcatalyst layer 34 is disposed only at the central portion 38 at which aflow rate of exhaust gas is increased, it is possible to favorablymaintain the purification performance of the honeycomb filter 200,suppress the increase in pressure loss, and further reduce themanufacturing cost.

In the honeycomb filter 100 shown in FIGS. 1 to 4, in a cross sectionorthogonal to the extending direction of the cells 2 of the honeycombstructure 4, the platinum group element-containing catalyst layer 14 isdisposed on the side of the inner surface of the partition walls 1surrounding the inflow cells 2 a of the entire area of the crosssection. It is preferable that the honeycomb filter 200 shown in FIGS. 5and 6 has the same structure as the honeycomb filter 100 shown in FIGS.1 to 4 except that the range in which the platinum groupelement-containing catalyst layer 34 is disposed is limited to thecentral portion 38 of the honeycomb structure 24.

(3) Method for Manufacturing Honeycomb Filter

The method for manufacturing a honeycomb filter according to the presentinvention is not particularly limited, and for example, the followingmethod can be mentioned.

First, a plastic kneaded material for manufacturing partition walls of ahoneycomb structure is prepared. The kneaded material for manufacturingthe partition walls of the honeycomb structure can be prepared byappropriately adding additives such as a binder, a pore former, andwater to a raw material powder for preparing a suitable material for theabove-mentioned partition walls. Examples of the raw material powder mayinclude powder of alumina, talc, kaolin, and silica. Examples of thebinder may include methylcellulose, hydroxypropyl methylcellulose or thelike. In addition, examples of the additive may include a surfactant

Next, a pillar honeycomb formed body having partition walls for defininga plurality of cells and a circumferential wall disposed to surround thepartition walls is prepared by extruding the thus obtained kneadedmaterial. Next, the obtained honeycomb formed body is dried withmicrowave and hot air, for example.

Next, the plugging portions are formed on the dried honeycomb formedbody. The method for forming plugging portions can be performedaccording to the conventionally known method for manufacturing ahoneycomb filter. For example, first, a mask is applied to the inflowend face of the honeycomb formed body so that the inflow cell iscovered. Thereafter, the end portion having the mask of the honeycombformed body is immersed in a plugging slurry, and an open end having nomask of the outflow cell is filled with the plugging slurry. Thereafter,even for the outflow end face of the honeycomb formed body, the open endof the inflow cell is filled with the plugging slurry by the same methodas described above. Thereafter, the honeycomb formed body having theplugging portions formed therein is further dried with a hot air dryer.

Next, the honeycomb formed body having the plugging portions formedtherein is fired to prepare a honeycomb filter precursor prior todisposing the platinum group element-containing catalyst layer. A firingtemperature and a firing atmosphere at the time of firing the honeycombformed body differ depending on a raw material for preparing thehoneycomb formed body, and those skilled in the art can select a firingtemperature and a firing atmosphere most suitable for the selectedmaterial.

Next, the platinum group element-containing catalyst for preparing theplatinum group element-containing catalyst layer is prepared. As theplatinum group element-containing catalyst, for example, a catalyst inwhich a platinum group element is loaded onto an aluminum oxide having aparticle diameter of 1 to 10 μm can be used. Such aluminum oxide isapplied in a zone coat within a range of at least up to 35% with respectto the overall length of the cells starting from the inflow end face ofthe honeycomb filter precursor. As a specific method of the zone coat,for example, the following methods can be mentioned. First, a catalystlayer forming slurry containing catalyst powder such as aluminum oxideonto which the platinum group element is loaded and an appropriatesolvent (for example, ion exchanged water) and a dispersing agent isprepared. Next, the catalyst layer forming slurry is poured from theinflow end face of the honeycomb filter precursor and sucked from theoutflow end face, such that the platinum group element-containingcatalyst is applied to the surface of the partition walls surroundingthe inflow cells in which the side of the inflow end face of thehoneycomb filter precursor is open. Thereafter, the zone-coated platinumgroup element-containing catalyst is fired at 500° C. to prepare theplatinum group element-containing catalyst layer. By adjusting at leastone of the viscosity of the catalyst layer forming slurry and thepressure at the time of suction, the platinum group element-containingcatalyst layer is disposed only on the surface of the partition walls.In addition, as a method of the zone coat, a platinum groupelement-containing catalyst layer can also be applied on the surface ofthe partition walls by dipping the catalyst layer forming slurry. Asdescribed above, the honeycomb filter according to the present inventioncan be manufactured.

EXAMPLES

Hereinafter, the present invention will be described more specificallywith reference to examples, but the present invention is not limited tothese examples.

Example 1

First, alumina, talc, kaolin, and silica raw materials for preparingpartition walls of a honeycomb structure were prepared. 2 parts by massof a dispersing medium and 7 parts by mass of an organic binder wereeach added to the prepared alumina, talc, kaolin, and silica rawmaterials (total 100 parts by mass), mixed, and kneaded to preparekneaded material. As the dispersing medium, water was used. As theorganic binder, methyl cellulose was used. As the dispersing agent, asurfactant was used.

Next, the kneaded material was extruded using a die for preparing ahoneycomb formed body to obtain a honeycomb formed body whose overallshape is a round pillar shape. The shape of the cell of the honeycombformed body was a rectangle.

Next, after the honeycomb formed body was dried by a microwave dryer andcompletely dried by a hot air dryer again, both end faces of thehoneycomb formed body were cut and adjusted to predetermined dimensions.

Next, plugging portions were formed on the dried honeycomb formed body.Specifically, first, a mask was applied to the inflow end face of thehoneycomb formed body so that the inflow cell is covered. Thereafter,the end portion having the mask of the honeycomb formed body is immersedin a plugging slurry, and an open end having no mask of the outflow cellis filled with the plugging slurry. Thereafter, even for the outflow endface of the honeycomb formed body, the open end of the inflow cell isfilled with the plugging slurry by the same method as described above.Thereafter, the honeycomb formed body having the plugging portionsformed therein is further dried with a hot air dryer.

Next, the dried honeycomb formed body was degreased and fired to preparea honeycomb filter precursor prior to disposing the platinum groupelement-containing catalyst layer.

Next, the platinum group element-containing catalyst layer was preparedon the side of the inner surface of the partition walls surrounding theinflow cells of the honeycomb filter precursor by the following method.First, a catalyst layer forming slurry containing a powder of aluminumoxide onto which palladium as a platinum group element is loaded, ionexchanged water, and a dispersing agent was prepared. Next, the catalystlayer forming slurry was poured from the inflow end face of thehoneycomb filter precursor, and the poured catalyst layer forming slurrywas sucked from the outflow end face while adjusting a pressure at thetime of suction so that the platinum element-containing catalyst layeris applied only to the inner surface of the partition walls. By doingso, the platinum group element-containing catalyst was applied to thesurface of the partition walls surrounding the inflow cells in which theside of the inflow end face of the honeycomb filter precursor is open.Thereafter, the platinum group element-containing catalyst applied tothe surface of the partition walls was fired at 500° C. to prepare theplatinum group element-containing catalyst layer.

The shape of the honeycomb filter of Example 1 was a round pillar shapein which the shape of the inflow end face and the outflow end face was acircle. In addition, a length in an extending direction of the cells ofthe honeycomb filter was 127 mm. A diameter of the end face of thehoneycomb filter was 118 mm. In the honeycomb structure constituting thehoneycomb filter, a thickness of the partition wall was 0.22 mm, and acell density was 47 cells/cm². A porosity of the partition walls of thehoneycomb structure was 63%.

In addition, the platinum group element-containing catalyst layer wasdisposed only on the side of the inner surface of the partition wallssurrounding the inflow cells. The platinum group element-containingcatalyst layer was disposed in a range (that is, a range of 60% withrespect to the overall length of the cells starting from the inflow endface) of up to 60% with respect to the overall length of the cellsstarting from the inflow end face of the honeycomb structure. A porosityof the platinum group element-containing catalyst layer was 65%. Table 1shows a disposition range and a disposition spot of the platinum groupelement-containing catalyst

TABLE 1 Disposition range Disposition spot of platinum of platinum groupelement- group element- containing catalyst containing catalystComparative 100% In pore of partition wall Example 1 Comparative 60%from In pore of partition wall Example 2 inflow end face Example 1 60%from Surface of partition wall inflow end face surrounding inflow cellExample 2 50% from Surface of partition wall inflow end face surroundinginflow cell Example 3 40% from Surface of partition wall inflow end facesurrounding inflow cell Example 4 35% from Surface of partition wallinflow end face surrounding inflow cell Example 5 70% from Surface ofpartition wall inflow end face surrounding inflow cell

With respect to the honeycomb filter of Example 1, “trapping efficiencyperformance”, “pressure loss performance”, and “exhaust gas purificationperformance” were evaluated by the following method. The results areshown in Table 2.

(Trapping Efficiency Performance)

First, an exhaust gas purifying apparatus using a honeycomb filter ofeach example as an exhaust gas purifying filter was manufactured. Themanufactured exhaust gas purification apparatus was connected to a sideof an outlet of an engine exhaust manifold of a 1.2 L direct injectiontype gasoline engine vehicle to measure the number of soot contained inthe gas emitted from the outlet of the exhaust gas purificationapparatus by a PN measurement method. The “PN measurement method” is ameasurement method proposed by a particle measurement program(abbreviated as PMP) at the Conference of Exhaust Gas Energy Experts(abbreviated as GRPE) of Automobile Standard Harmonized World Forum(abbreviated as WP29) in the European Economic Committee (abbreviated asECE) of the United Nations (abbreviated as UN). Specifically, in thedetermination of the number of soot, the cumulative number of sootemitted after traveling in a Worldwide harmonized Light duty Test Cycle(WLTC) mode is defined as the number of soot of the exhaust gaspurifying apparatus to be determined, and the trapping efficiency ismeasured. The trapping efficiency performance was evaluated on the basisof the following evaluation criteria which were based on the measuredvalues of each trapping efficiency. When the values of the trappingefficiency of the exhaust gas purifying apparatus using the honeycombfilter of Comparative Example 1 was set to be 100% in a column of“trapping efficiency ratio (%)” in the following Table 2, the values (%)of the trapping efficiency of the exhaust gas purifying apparatus usingthe honeycomb filters of each example were shown.

Evaluation “excellent”: When the value of the trapping efficiency of theexhaust gas purifying apparatus using the honeycomb filter ofComparative Example 1 was set to be 100% and when the value of thetrapping efficiency of the exhaust gas purifying apparatus using thehoneycomb filter to be evaluated was 120% or more, the evaluation was“excellent”.

Evaluation “good”: When the value of the trapping efficiency of theexhaust gas purifying apparatus using the honeycomb filter ofComparative Example 1 was set to be 100% and when the value of thetrapping efficiency of the exhaust gas purifying apparatus using thehoneycomb filter to be evaluated exceeded 110% and was less than 120%,the evaluation was “good”.

Evaluation “permission”: When the value of the trapping efficiency ofthe exhaust gas purifying apparatus using the honeycomb filter ofComparative Example 1 was set to be 100% and when the value of thetrapping efficiency of the exhaust gas purifying apparatus using thehoneycomb filter to be evaluated exceeded 100% and was 110% or less, theevaluation was “permission”.

(Pressure Loss Performance)

Exhaust gas emitted from a 1.4 L direct injection type gasoline enginewas introduced into honeycomb filters of each example and soot in theexhaust gas was trapped in partition walls of the honeycomb filter. Thesoot was trapped until the amount of soot deposited per unit volume (1L) of the honeycomb filter reached 1 g/L. Then, the engine exhaust gasof 200° C. was flowed in at a flow rate of 1.0 Nm³/min in a state inwhich the deposited amount of soot was 1 g/L, and the pressure betweenthe side of the inflow end face and the side of the outflow end face ofthe honeycomb filter was measured. Then, a pressure loss (kPa) of thehoneycomb filter was obtained by calculating a pressure differencebetween the side of the inflow end face and the side of the outflow endface. The pressure loss performance was evaluated on the basis of thefollowing evaluation criteria which were based on the measured values ofeach pressure loss. In the column of “pressure loss ratio (%)” in thefollowing Table 2, values (%) of the pressure loss of the honeycombfilters of each example were shown when the value of the pressure lossof the honeycomb filter of Comparative Example 1 was 100%.

Evaluation “excellent”: When the value of the pressure loss of thehoneycomb filter of Comparative Example 1 was set to be 100% and whenthe value of the pressure loss of the honeycomb filter to be evaluatedwas less than 90%, the evaluation was “excellent”.

Evaluation “good”: When the value of the pressure loss of the honeycombfilter of Comparative Example 1 was set to be 100% and when the value ofthe pressure loss of the honeycomb filter to be evaluated was 90% ormore and less than 95%, the evaluation was “good”.

Evaluation “permission”: When the value of the pressure loss of thehoneycomb filter of Comparative Example 1 was set to be 100% and whenthe value of the pressure loss of the honeycomb filter to be evaluatedwas 95% or more and less than 100%, the evaluation was “permission”.

(Exhaust Gas Purification Performance)

First, an exhaust gas purifying apparatus using a honeycomb filter ofeach example as an exhaust gas purifying filter was manufactured. Themanufactured exhaust gas purification apparatus was connected to a sideof an outlet of an engine exhaust manifold of a 1.2 L direct injectiontype gasoline engine vehicle to measure a concentration of NOx containedin the gas emitted from the outlet of the exhaust gas purificationapparatus and obtain a purification efficiency of NOx. The exhaust gaspurification performance was evaluated on the basis of the followingevaluation criteria which were based on the measured values of thepurification efficiency of each NOx. When the values of the purificationefficiency of NOx of the exhaust gas purifying apparatus using thehoneycomb filter of Comparative Example 1 was set to be 100% in a columnof “purification efficiency ratio (%) of NOx” in the following Table 2,the values (%) of the purification efficiency of NOx of the exhaust gaspurifying apparatus using the honeycomb filters of each example wereshown.

Evaluation “excellent”: When the value of the purification efficiency ofNOx of the exhaust gas purifying apparatus using the honeycomb filter ofComparative Example 1 was set to be 100% and when the value of thepurification efficiency of NOx of the exhaust gas purifying apparatususing the honeycomb filter to be evaluated exceeded 125%, the evaluationwas “excellent”.

Evaluation “good”: When the value of the purification efficiency of NOxof the exhaust gas purifying apparatus using the honeycomb filter ofComparative Example 1 was set to be 100% and when the value of thepurification efficiency of NOx of the exhaust gas purifying apparatususing the honeycomb filter to be evaluated was 120% or more and 125% orless, the evaluation was “good”.

Evaluation “permission”: When the value of the purification efficiencyof NOx of the exhaust gas purifying apparatus using the honeycomb filterof Comparative Example 1 was set to be 100% and when the value of thepurification efficiency of NOx of the exhaust gas purifying apparatususing the honeycomb filter to be evaluated exceeded 100% and was lessthan 120%, the evaluation was “permission”.

Evaluation “no permission”: When the value of the purificationefficiency of NOx of the exhaust gas purifying apparatus using thehoneycomb filter of Comparative Example 1 was set to be 100% and whenthe value of the purification efficiency of NOx of the exhaust gaspurifying apparatus using the honeycomb filter to be evaluated was 100%or less, the evaluation was “no permission”.

TABLE 2 Purification Trapping Purification Trapping Pressure efficiencyTrapping Exhaust gas efficiency Pressure efficiency of efficiency lossratio ratio of efficiency Pressure loss purification (%) loss (kPa) NOx(%) ratio (%) (%) NOx (%) performance performance performanceComparative 60.00 3.00 60 100% 100% 100% Criterion Criterion CriterionExample 1 Comparative 64.00 2.96 50 107% 99% 83% Permission PermissionNo permission Example 2 Example 1 75.00 2.80 75 125% 93% 125% ExcellentGood Good Example 2 73.00 2.75 72 122% 92% 120% Excellent Good GoodExample 3 71.00 2.70 69 118% 90% 115% Good Good Permission Example 470.00 2.68 68 117% 89% 113% Good Excellent Permission Example 5 77.002.85 78 128% 95% 130% Excellent Permission Excellent

Examples 2 to 5

Honeycomb filters were prepared in the same method as Example 1 exceptthat a disposition range and a disposition spot of a platinum groupelement-containing catalyst were changed as shown in the above Table 1.With respect to the honeycomb filters of Examples 2 to 5, “trappingefficiency performance”, “pressure loss performance”, and “exhaust gaspurification performance” were evaluated by the same method asExample 1. The results are shown in Table 2.

Comparative Examples 1 and 2

Honeycomb filters were prepared in the same method as Example 1 exceptthat a disposition range and a disposition spot of a platinum groupelement-containing catalyst were changed as shown in the above Table 1.In Comparative Examples 1 and 2, as in the following methods, theplatinum group element-containing catalyst was loaded into the innerportion of pores of partition walls of a honeycomb structure. In theComparative Example 1, first, a catalyst layer forming slurry containinga catalyst powder of aluminum oxide onto which a platinum group elementis loaded, ion exchanged water, and a dispersing agent was prepared.Next, the platinum group element-containing catalyst was applied to theentire surface of partition walls of a honeycomb filter precursor byimpregnating the catalyst layer forming slurry from an inflow end faceand an outflow end face of the honeycomb filter precursor. Thereafter,the platinum group element-containing catalyst was fired at 500° C. toprepare the platinum group element-containing catalyst layer. InComparative Example 2, by impregnating the above-described catalystlayer forming slurry from the inflow end face of the honeycomb filterprecursor, the platinum group element-containing catalyst was loadedinto the inner portion of pores of the partition walls in a range of 60%from the inflow end face of the honeycomb filter precursor.

(Result)

It was confirmed that the honeycomb filters of Examples 1 to 5 exceededthe respective performances of the honeycomb filter of ComparativeExample 1 serving as a reference, in all evaluations of the “trappingefficiency performance”, the “pressure loss performance”, and the“exhaust gas purification performance”. Therefore, it has been foundthat the honeycomb filters of Examples 1 to 5 are also excellent in thetrapping performance and the purification performance, and can suppressthe increase in the pressure loss as compared with the conventionalhoneycomb filter. On the other hand, compared with the honeycomb filterof Comparative Example 1, in the honeycomb filter of Comparative Example2, the improvement in the “trapping efficiency performance” and the“pressure loss performance” was hardly observed, whereas the “exhaustgas purifying performance” was extremely inferior.

The honeycomb filter according to the present invention can be used asthe filter for trapping the particulate matter in the exhaust gas.

DESCRIPTION OF REFERENCE NUMERALS

-   -   1 and 21: partition wall, 2 and 22: cell, 2 a and 22 a: inflow        cell, 2 b and 22 b: outflow cell, 3 and 23: circumferential        wall, 4 and 24: honeycomb structure, 5 and 25: plugging portion,        11 and 31: inflow end face, 12 and 32: outflow end face, 14 and        34: platinum group element-containing catalyst layer, 38:        central portion, and 100 and 200: honeycomb filter.

What is claimed is:
 1. A honeycomb filter, comprising: a honeycomb structure which has porous partition walls disposed so as to surround a plurality of cells as through channels of fluid extending from an inflow end face to an outflow end face; and plugging portions disposed to plug either one of end portions of each of the cells on the side of the inflow end face or the side of the outflow end face, wherein the cells in which the plugging portions are arranged in an end portion on the side of the outflow end face and which are opened on the side of the inflow end face are defined as inflow cells, the cells in which the plugging portions are arranged in end portion on the side of the inflow end face and which are opened on the side of the outflow end face are defined as outflow cells, the honeycomb structure further includes a platinum group element-containing catalyst layer constituted by an exhaust gas purifying catalyst containing a platinum group element, the platinum group element-containing catalyst layer is directly disposed only on a side of an inner surface of the partition walls surrounding the inflow cells, and the platinum group element-containing catalyst layer is disposed in a range of at least 35% with respect to an overall length of the cells starting from the inflow end face and is not disposed in a range of at least 30% with respect to the overall length of the cells starting from the outflow end face, in an extending direction of the cells of the honeycomb structure.
 2. The honeycomb filter according to claim 1, wherein a porosity of the platinum group element-containing catalyst layer is from 50 to 90%.
 3. The honeycomb filter according to claim 1, wherein a thickness of the platinum group element-containing catalyst layer is from 10 to 40 μm.
 4. The honeycomb filter according to claim 1, wherein the platinum group element-containing catalyst layer is a catalyst layer containing an oxide of at least one element selected from the group consisting of aluminum, zirconium, and cerium.
 5. The honeycomb filter according to claim 1, wherein in a cross section orthogonal to the extending direction of the cells of the honeycomb structure, a range within 60% of a length from a center of gravity of the cross section to a circumferential edge of the cross section is defined as a central portion of the cross section, and the platinum group element-containing catalyst layer is disposed on the partition wall present at the central portion of the cross section.
 6. The honeycomb filter according to claim 1, wherein in the cross section orthogonal to the extending direction of the cells of the honeycomb structure, the platinum group element-containing catalyst layer is disposed on the partition walls which surround the inflow cells in an entire area of the cross section. 